Hydronic Wall Panel

ABSTRACT

In various example embodiments, a multi-layer wall structure is described, comprising an interior wall layer, a waterproof channel layer comprising adjacent parallel channels running from an upper manifold down to a lower manifold which is fed by and a remote fluid source. The multi-layer wall structure further provides structural support for a building and may be a wall, ceiling, or floor, and wherein the multi-layer wall structure may heat or cool a living space.

BACKGROUND Field of the Invention

This invention generally relates to buildings and more particularlyrelates to heating and cooling a building.

Background of the Invention

There are many ways to heat or cool a living space. The current artincludes furnaces, boilers, heat pumps, gas-fired space heaters,electric space heaters, wood-burning and pellet stoves, fire places,ductless, and radiant heating. Radiant heating is advantageous becauseit allows for greater efficiency and zoning, is silent, and doesn'tcirculate allergens.

Current art radiant heat systems are normally installed in floors, butare also installed in walls and the ceiling. Current art most often usesPEX pipes or another type of pipe. They are placed throughout the floor,wall, or ceiling. Water then circulates through the pipes varying intemperature to either heat or cool the surrounding living area. Thesesystems offer no structural support for the buildings where they areinstalled. In addition, they represent a small portion of the surfacearea where they are installed. This can result in uneven heating,especially when objects are placed in front of or over top of theradiant heating/cooling system. For example, couches, bookshelves, andpictures or clocks that are hung on walls will impede the heating orcooling process.

Other known radiant flooring systems are configured such that the pipesare installed and concrete is laid over top of them to comprise thefloor of the building or living area. This makes the installationprocess cumbersome and expensive, and also impedes the heating orcooling process. A radiant heat system is needed that may comprise thefloor itself, so that minimal material is placed between the fluid—thesource of the heating or cooling—and the living area.

A system is needed that comprises the entire surface area of a wall,ceiling or floor. Such a system will allow for more efficient andconsistent heating and cooling. A system that can be easily manufacturedwith the fluid pathway integrated within the wall, floor, or ceilingpanel could potentially simplify the manufacturing process, and reducethe total system cost. A radiant heat system which offers structuralsupport for the building is also needed. Embodiments disclosed hereinmay improve performance of radiant heat systems.

SUMMARY

This invention has been developed in response to the present state ofthe art and, in particular, in response to the problems and needs in theart that have not yet been fully solved by currently available systemsand methods. Features and advantages of different embodiments of theinvention will become more fully apparent from the following descriptionand appended claims, or may be learned by practice of the invention asset forth hereinafter.

Consistent with the foregoing, a structure for heating or cooling aliving area that simultaneously provides structural support for thebuilding is disclosed. Rather than have pipes embedded inside the wallstructure, the structural material itself is configured with parallelchannels running through the panel. These channels allow fluid flowthroughout the panel for heating or cooling the space.

The structure includes: A multi-layer wall structure, comprising aninterior wall layer; a waterproof channel layer comprising adjacentparallel channels in communication with each other, a structural layer,a channel layer perpendicular to the waterproof channel layer, a thermalinsulation layer, an outer layer, and an upper manifold and lowermanifold in communication with the adjacent parallel channels and aremote fluid source.

The waterproof channel layer and channel layer perpendicular to thewaterproof channel layer may be composed from different materials suchas polycarbonate, acrylic, plastic, polypropylene, or non-woodmaterials. All these materials are waterproof and won't mold, mildew, ordeteriorate when water or another hydronic fluid is run through thewater proof channel layer. Additionally, the shapes of the channels mayvary. The channels are parallel and evenly spaced, but the specificshape may be hexagon, octagon, triangle, quadrilateral, pentagon,heptagon, nonagon, decagon or another shape. The waterproof channellayer and channel layer perpendicular to it are designed such that theperpendicular channels add sheer strength to the structure.

The multi-layer wall structure also adds structural support for thebuilding wherein it is placed. The sheer strength created by thewaterproof channel layer and channel layer perpendicular to it, as wellas the structural layer provide structural support. The fluid runningfrom either the upper manifold to lower manifold or the lower manifoldto the upper manifold is heated or cooled by a central water heatingsystem. When it flows through the waterproof channel layer, the heatradiates into the living area in order to heat or cool the living space.The channel layer perpendicular to the waterproof channel layer and thethermal insulation provide insulation in the multi-layer wall structure.The air inside the channel layer perpendicular to the waterproof channellayer insulates. The thermal insulation layer may be a foam board, rigidfoam, aluminum foil, or another insulating material that will reflectthe heat inwards toward the living area. Furthermore, the structurallayer will also reflect heat into the living area. It will be reflectiveitself, have a reflective coating, or a reflective film adhesivelyattached.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readilyunderstood, a more particular description of the invention brieflydescribed above will be rendered by reference to specific embodimentsillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered limiting of its scope, the invention will be describedand explained with additional specificity and detail through use of theaccompanying drawings, in which:

FIG. 1 is an isometric section view of a multi-layer wall structure,according to one example embodiment.

FIG. 1B is an isometric section view of a multi-layer wall structure,according to one example embodiment.

FIG. 2 is an isometric section view of certain sections of the wallstructure, according to one example embodiment.

FIG. 3A is a partial wall section of the multi-layer wall structureillustrating how fluid flow through the waterproof channel layer,according to one example embodiment.

FIG. 3B is a partial wall section of the multi-layer wall structureillustrating how fluid flow through the waterproof channel, according toone example embodiment.

FIG. 4 is an isometric view of a room with a section view of amulti-layer wall structure next to it, according to one exampleembodiment.

FIG. 5 is an isometric view of the wall structure with an extendedstructural layer, according to one example embodiment.

FIG. 6 is an isometric view of a room with a section view of amulti-layer wall structure utilized as a ceiling structure, according toone example embodiment.

FIG. 7 is a flow diagram showing the wall structure connected to aheating and cooling system, according to one example embodiment.

FIGS. 8A, 8B and 8C are example embodiments of channels of variousextruded shapes, according to certain example embodiments.

FIG. 9 is an isometric view of a multi-layer wall structure illustratinghow fluid flows thru the channel layers, according to one exampleembodiment.

FIG. 10A is an isometric view of a multi-layer wall structureillustrating how fluid flows thru the channel layers, according to oneexample embodiment, according to one example embodiment.

FIG. 10B is an isometric view of a multi-layer wall structureillustrating how fluid flows thru the channel layers in another exampleembodiment.

FIG. 10C is an isometric view of a multi-layer wall structureillustrating how fluid flows thru the channel layers in an exampleembodiment.

DETAILED DESCRIPTION OF THE DRAWINGS

The description that follows includes systems, methods, techniques,instruction sequences, and computing machine program products thatembody illustrative embodiments of the disclosure. In the followingdescription, for the purposes of explanation, numerous specific detailsare set forth in order to provide an understanding of variousembodiments of the inventive subject matter. It will be evident,however, to those skilled in the art, that embodiments of the inventivesubject matter may be practiced without these specific details. Ingeneral, well-known instruction instances, protocols, structures, andtechniques are not necessarily shown in detail.

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment. Thus, appearances of the phrases“in one embodiment,” “in an embodiment,” and similar language throughoutthis specification may, but do not necessarily, all refer to the sameembodiment, but mean “one or more but not all embodiments” unlessexpressly specified otherwise. The terms “including,” “comprising,”“having,” and variations thereof mean “including but not limited to”unless expressly specified otherwise. An enumerated listing of itemsdoes not imply that any or all of the items are mutually exclusiveand/or mutually inclusive, unless expressly specified otherwise. Theterms “a,” “an,” and “the” also refer to “one or more” unless expresslyspecified otherwise.

Furthermore, the described features, advantages, and characteristics ofthe embodiments may be combined in any suitable manner. One skilled inthe relevant art will recognize that the embodiments may be practicedwithout one or more of the specific features or advantages of aparticular embodiment. In other instances, additional features andadvantages may be recognized in certain embodiments that may not bepresent in all embodiments.

The liquid that flows through the waterproof channel layer may be wateror any other hydronic fluid which includes oil.

There are many existing radiant heating systems which use PEX pipe orother similar piping. The multi-layer wall structure is advantageousbecause it uses the entire surface area of the wall to radiantly heat orcool a living area. This will allow for greater flexibility whenindividuals living in, renting, or using the living area would like toadd furniture, decorations, clocks, paintings, light fixtures, bookshelves, cabinets or other furniture to the living area. In pex piperadiant heating systems, the listed furniture causes a lot of problemsbecause when the pipes only cover a very small portion of the surfacearea. Using furniture then blocks a greater percentage of the heat orcooling.

The water or other hydronic fluid may be pumped from the bottom manifoldto the top manifold or from the top manifold to the bottom manifold.There are advantages with each embodiment. When the water is pumped fromthe top manifold to the bottom manifold, the flow of water does not haveto work against gravity. This will make pumping the water downwards moreefficient and save more energy for owners of a building with amulti-layer wall structure. However, it may also be advantageous to pumpwater or another hydronic fluid from the bottom manifold to the topmanifold because individuals in the living area are on the floor, and sothe warmest part of that wall would be nearest the people by pumpingfrom bottom manifold to top.

There are various shapes that the channels of the waterproof channelsmay be shaped into the channels are parallel to one another and evenlyspaced and cover the surface area of the wall, ceiling, or floor wherethey are installed. One special advantage of the waterproof channelswhen compared to current art radiant heating systems is the issue of aleak. Current art radiant heating systems are extremely costly toinstall and are most often laid in floors and covered with a layer ofconcrete. Not only does this inhibit the heating or cooling effects, butmakes repair very expensive whenever there is a leak in the pipes. theonly option when there is a leak is to remove the concrete and repairthe individual pipe that is the source of the problem. In contrast, inthe multi-layer wall structure, the channels through which the liquidflows are in communication with one another. That is to say, when thereis a leak or a break in one of the channels, the liquid will flow intothe channel adjacent to it and not out into the wall (which could causemolding, deterioration) thus small leaks in the multi-layer wallstructure do not require reparation. This also makes the multi-layerwall structure less expensive to maintain than current art radiantheating and cooling systems.

The multi-layer wall structure may be used as an exterior wall orinterior wall. In either embodiment, the thermal insulating layer isdesigned to direct the heat into the room that the waterproof channellayer is nearest. The channel layer perpendicular to the waterproofchannel layer also contributes to directing the heat towards theintended room. This way, heat does not escape into a room or outdoorarea behind the multi-layer wall structure. By using a thermalinsulating layer, owners of a multi-layer wall structure can also usezoning, that is they can heat specific rooms that they need to withoutleaking a lot of heat into surrounding rooms an insulating layer may bea foam board. The foam board is also useful in its ability to dampensound traveling through rooms. It will help to control noise fromtraveling from room to room. The channel layer perpendicular to thewaterproof channel layer can also provide the insulation necessary todirect the heat into the living area.

The structural layer may also contribute to insulating. In the preferredembodiment, the structural layer is made from a metal that has thenatural attribute of being reflective to direct heat into the livingarea. In another embodiment, the metal sheet layer has a reflectivecoating so that the desired effect is still achieved. Another embodimentincludes a reflective material being placed over the structural layerwhich has reflective properties and will also direct the heat into theliving area.

There are a number of ways to heat fluid in a building. Any currentfluid heating system will work with the multi-layer wall structure. Thehydronic fluid is pumped from the heating system to the upper or lowermanifold. When the hydronic fluid exits the upper or lower manifold itis returned to the central water heating system and reheated or cooledto be circulated through the system again. Depending on the buildingtype wherein the multi-layer wall structure is installed, one centralfluid heating and cooling system may be preferred over another.

the multi-layer wall structure layers may be different than the orderpresented in various embodiments throughout the description containedherein. There are several embodiments that may be preferred depending onwhether the multi layer wall structure is used as a ceiling, wall, orfloor. The structural layer provides strength in addition to the sheerstrength that is generated by the waterproof channel layer beingperpendicular to the second channel layer. When the structure is used asa floor, the structural layer will be thicker to increase the maximumload bearing. The multi-layer wall structure as a floor will need tosupport more weight at any time because of furniture and a varyingnumber of people in the room. The wall and ceiling will not need to bearthat load. Additional sheer and loading strength is achieved bystructurally or adhesively connecting vertical channel layers withadjacent horizontal channel layers. Many examples of this are shown bothin these written specifications and drawings contained herein.

These features and advantages of the embodiments will become more fullyapparent from the following description and appended claims, or may belearned by the practice of embodiments as set forth hereinafter.

FIG. 1 is an isometric section view of a multi-layer wall structure. Themulti-layer wall structure 110 is shown with an interior wall layer 112facing the interior space of the area to be heated or cooled. In certainembodiments, a metamaterial 114 is placed between the waterproof channellayer 120. The metamaterial 114 enhances the heat transfer from thewaterproof channel layer 120 to the area to be heated or cooled. Thevertical channels 118 open into the manifold to allow fluid to flow fromthe manifold into the channels. In one embodiment, fluid flows from theupper manifold 140 and through the channels 118 down to the lowermanifold 142. In another embodiment, the fluid flows from the lowermanifold 142 up to the upper manifold 140.

In the embodiment shown in FIG. 1, the structural layer 126 is between achannel layer 124 and a thermal insulation layer 130. In thisembodiment, the insulation also insulates the upper and lower manifolds.As shown in this embodiment, the waterproof channel layer 118 is coatedwith a heat reflective material 122. An outer layer 132 is shown facingthe exterior of the building in certain embodiments. In otherembodiments, the outer layer 132 is facing another room inside abuilding. In this case, the wall structure 110 is an interior wall, andthe heating or cooling is only required in the room it is facing. Thisallows each wall structure to serve individual rooms both within theinterior space of the building, and where the wall structure is anexterior wall. An advantage of this configuration is that the heatingand cooling of each room or area within the building that has amulti-layer wall structure can be controlled separately. This providesmore control by allowing occupants of each individual room or spacewithin the building to be able to adjust the temperature settings of thewall structure that serves their own area.

FIG. 1B is an isometric section view of a multi-layer wall structure.The multi-layer wall structure 110 is shown with an interior wall layer112 facing the interior space of the area to be heated or cooled. In oneembodiment, fluid flows from the upper manifold 140 and through thewaterproof channel layer 120 down to the lower manifold 142.

In the embodiment shown in FIG. 1B, the structural layer 126 is extendedfrom the bottom of the wall structure 150 up to the top of the wallstructure 152. This provides continuous structural support from thebottom of the structure to the top. The channel layer 124 and a thermalinsulation layer 130, and outer layer 132 may also be extended from thebottom of the wall structure all the way to the top as shown.

FIG. 2 is an isometric section view of certain sections of the wallstructure showing the structural layer 126 in between the waterproofchannel layer 120 and perpendicular channel layer 124. In thisembodiment, the structural support layer is facing the waterproofchannel layer and is coated with heat reflecting material 122.

FIG. 3A is a partial wall section of the multi-layer wall structureillustrating how fluid flow through the waterproof channel layer 120.Horizontal channel 124 is shown directly adjacent to the structurallayer 126. These two layers may be adhesively attached to each other,and the structural layer 126 may be adhesively attached to thewaterproof channel layer 120. In this example embodiment, fluid 310flows from the upper manifold 140 down to the lower manifold 142.

FIG. 3B is a partial wall section of the multi-layer wall structureillustrating how fluid flow through the waterproof channel layer 120.Horizontal channel 124 is shown directly adjacent to the structurallayer 126. These two layers may be adhesively attached to each other,and the structural layer 126 may be adhesively attached to thewaterproof channel layer 120. In this example embodiment, fluid 310flows from the lower manifold 142 up to the upper manifold 140.

FIG. 4 is an isometric view of a room with a section view of amulti-layer wall structure next to it. Upper manifold 140 and lowermanifold 142 are shown, along with outer layer 132. The heat 420 fromheated fluid flowing through waterproof channel layer 120 penetrates theinterior wall layer 112 and extends into the room 410. In certainembodiments, the interior wall layer 112 allows heat to flow thru thewall material into the room. In an embodiment, the interior further issound dampening.

FIG. 5 is an isometric view of the wall structure with an extendedstructural layer. In this embodiment, the structural layer 510 extendsbeyond the other wall layers. This allows the wall structure to bestructurally attached to adjacent structural members such as adjacentwalls, floors or ceiling structures. Thermal insulation layer 130,interior wall layer 112, and outer layer 132 are shown, along withchannel layer 124. In this embodiment, upper manifold 140 and lowermanifold 142 are cylindrical in shape, and may be a pipe that allowsfluid flow into the waterproof channel layer 120.

FIG. 6 is an isometric view of a room with a section view of amulti-layer wall structure utilized as a ceiling structure 610. Uppermanifold 140 and lower manifold 142 are shown, channel layer 124, alongwith waterproof channel layer 120. In this embodiment, the ceilingstructure 610 provides heating to a room. Wall 605 and floor 602 areshown defining the room space.

FIG. 7 is a flow diagram showing the wall structure connected to aheating and cooling system. Pump 720 pumps fluid from the heating andcooling system 710 via supply piping 726 into the wall structure lowermanifold 142. Fluid flow 736 is represented by an arrow, showing thedirection of flow entering the wall structure's lower manifold 142. Thefluid continues up thru the waterproof channel layer, and to the uppermanifold 140. Fluid flow 734 continues into return piping 724 to theheating and cooling system 710.

FIGS. 8A, 8B and 8C are example embodiments of channels of variousextruded shapes. FIG. 8A shows square shaped channels 810, FIG. 8B showstriangular shaped channels 820, and FIG. 8C shows honeycomb shapedchannels 830.

FIG. 9 is an isometric view of a multi-layer wall structure illustratinghow fluid flows thru the channel layers. Fluid 910 enters supply piping940 into horizontal channel layer 124. The fluid then flows towardsopenings 914 between the horizontal channel layer and the verticalwaterproof channel layer 120, fluid 916 flowing down towards the lowermanifold. In this embodiment, the horizontal channel layer is alsowaterproof, and serves as a pathway for the fluid to flow across theseries of vertical waterproof channels. This allows for unique flowpatterns to be configured as required. For certain applications it maybe advantageous to have the fluid flowing both up the vertical channelsand down adjacent vertical channels.

FIG. 10A is an isometric view of a multi-layer wall structureillustrating how fluid flows thru the channel layers, according to oneexample embodiment. Fluid 1010 enters supply piping 940 into upperhorizontal channel layer 1012. The fluid then flows 1014 down to lowerhorizontal channel layer 1016, then out thru outlet piping 1040. Fluidflow 1020 shows the fluid exiting the wall structure.

FIG. 10B is an isometric view of a multi-layer wall structureillustrating how fluid flows thru the channel layers in another exampleembodiment. Fluid 1010 enters supply piping 940 into upper horizontalchannel layer 1012. In this embodiment, fluid 1030 flows back up to theupper channel layer 1012, then the fluid 1032 flows back down to lowerhorizontal channel layer 1016, then out thru outlet piping 1040. Fluidflow 1020 shows the fluid exiting the wall structure.

FIG. 10C is an isometric view of a multi-layer wall structureillustrating how fluid flows thru the channel layers in an exampleembodiment. Fluid 1010 enters supply piping 940 into upper horizontalchannel layer 1012. In this embodiment, fluid 1014 flows down to lowerhorizontal channel layer 1016, then fluid flows 1042 back up to theupper channel layer 1012, fluid 1044 flows back down to lower horizontalchannel layer 1016, then fluid flow 1030 returns back up to upperhorizontal channel layer 1012, and out thru outlet piping 1040. Fluidflow 1020 shows the fluid exiting the wall structure.

Regarding the structural layer materials, wherein sheet metal is usedfor the structural layer, fabrication applies to sheets comprising SPCC,SHCC, SECC, SGCC, copper plates, aluminum plate (6061,6063,5052,1020,etc), aluminum extrusion and stainless steel. Various materials withdifferent specifications may be utilized as follows: Steel platecold-rolled (SPCC). Mainly used for part need painted orelectro-plating, thickness usually no more than 3.2 mm; Hot rolled steel(SHCC). T≥3.0 mm, treated with spraying or electro plating as SPCC;Electro or Galvanized steel (SECC/SGCC). SECC includes N and P type;Copper plate. Mainly applied for electricity conducting function,surface treated with chrome or nickel plating, or without any finish;Aluminum plate. Usually treated with chromate, anodize (conductiveanodizing or chemical anodizing), may be silver or nickel plated;Aluminum extrusion are with complex structure from side view, itssurface can be treated as what aluminum plates do; and stainless steelsheet.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the invention is, therefore, indicatedby the appended claims rather than by the foregoing description. Allchanges which come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

1. A multi-layer wall structure, comprising: an interior wall layer; awaterproof channel layer comprising adjacent parallel channels incommunication with each other; a structural layer; one or more channellayers perpendicular to the waterproof channel layer; a thermalinsulation layer; an outer layer; an upper manifold in communicationwith the adjacent parallel channels; a lower manifold in communicationwith the adjacent parallel channels; a remote fluid source; and whereinthe upper manifold, lower manifold waterproof channel layer are incommunication with the fluid of the remote fluid source.
 2. Thestructure of claim 1, wherein the waterproof channel layer and the oneor more channel layers perpendicular to the waterproof channel layercomprise one or more materials and composites of: polycarbonate;acrylic; plastic; polystyrene; polypropylene; PVC; ABS; fiberglass;resin; crystalline materials; amorphous materials; organic materials;and synthetic materials.
 3. The structure of claim 1, wherein the remotefluid source flowing through the waterproof channel layer is a liquid.4. The structure of claim 3, wherein the liquid flowing through thewaterproof channel layer is at a temperature hot enough to radiantlyheat a living area.
 5. The structure of claim 3, wherein the liquidflowing through the waterproof channel layer is at a temperature coolenough to radiantly cool the living area.
 6. The structure of claim 1,wherein the multi-layer wall structure provides structural support for abuilding wherein it is placed.
 7. The structure of claim 1, wherein airis in the channel layer perpendicular to the waterproof channel layer toinsulate the living area.
 8. The structure of claim 3, wherein theliquid flowing through the waterproof channel layer enters and exits thewaterproof channel layer via the upper manifold or lower manifold. 9.The structure of claim 1, wherein the waterproof channel layer is coatedwith heat reflective material comprising one or more of foil; paint;metamaterials; fabric and metal coatings.
 10. The structure of claim 1,wherein the channels within the waterproof channel layer, and thechannels within the one or more channel layers are evenly spaced. 11.The structure of claim 4, wherein the channels within the waterproofchannel layer channels and the channels within the channel layercomprise extrusions of one or more of the shapes of: hexagon; octagon;triangle; quadrilateral; pentagon; heptagon; nonagon; decagon; shapesthat enhance fluid flow; and shapes that facilitate the manufacturing ofthe channels.
 12. The structure of claim 1, wherein the thermalinsulation layer comprises one or more materials of a foam board, rigidfoam, aluminum foil, and insulating material.
 13. The structure of claim1, wherein the structural layer reflects heat by one or more of thefollowing methods: coated with a reflective material; is reflectiveitself; has a coating on it that is reflective; and a reflective filmadhesively attached.
 14. The structure of claim 1, wherein one or moreadjacent channels of the waterproof channel layer are in communicationwith one or more channels of the one or more channel layers, and whereinthe one or more channel layers are waterproof.
 15. The structure ofclaim 1, wherein one or more layers of the multi-layer wall structurehave sound damping effects.
 16. The structure of claim 1, wherein themulti-layer wall structure is an interior wall, exterior wall, floor, orceiling.
 17. The structure of claim 1, wherein one or more layers of themulti-layer wall structure are coated with metamaterials comprising:glass-polymer hybrid materials with one or more properties of capturingheat; reflecting heat; shedding heat from the metamaterial; conductingheat; and transmitting heat.
 18. The structure of claim 1, wherein oneor more of each layer of the multi-layer wall structure is adhesivelyattached to another layer.
 19. The structure of claim 1, wherein thestructural layer comprises one or more materials and composites of:polycarbonate; acrylic; plastic; polystyrene; polypropylene; PVC; ABS;fiberglass; resin; crystalline materials; amorphous materials; organicmaterials; synthetic materials; steel; stainless steel; copper;aluminum; titanium; alloys and metal.
 20. The structure of claim 1,wherein the thermal insulating layer is the channel layer perpendicularto the waterproof channel layer.